Carpet cushion and backing fabric therefor



Oct. 16, 1962 R. S. HAVNER CARPET CUSHION AND BACKING FABRIC THEREFORFiled April 7, 1959 FIG. I

INVENTOR ROBERT S. HAVNER ATTORN Y ijnited The present invention relatesto an improved backing material for foam cushions, and more particularlyto a novel and improved woven fabric adapted especially for use as acushion backing. The invention also relates to foam cushionsincorporating the new backing material.

In connection with the manufacture of foam cushions for carpeting, forexample, it is conventional to provide a backing material, onto which acushion material, such as foam rubber, is poured or adhesively secured.The backing material supports the cushion material during the pouringand curing thereof and, in the finished cushion, forms a top surfaceupon which a rug or carpeting may be laid. The backing layer impartsdimensional stability to the foamed cushion material and also provides,when the cushion is laid down for use, a surface over which the rug orcarpeting may be slipped with relative ease.

Heretofore, it has been conventional to utilize for cushion backings awoven material, like burlap, which is formed of woven yarns of jute, forexample. However, such materials have been becoming in progressivelyincreasing short supply, to the point where, at the present time, it isdiflicult to obtain adequate quantities for dayto-day operations. Inaddition, the cost of such materials is becoming increasinglyburdensome.

Certain alternative materials have been proposed, for use in cushionbacking fabrics, one of which is yarn formed of twisted kraft paper.However, insofar as I am aware, such alternative materials have notproven to be satisfactory due, among other reasons, to high cost ofmanufacturing conventional fabrics of equivalent density.

In accordance with the invention, a novel and improved cushion backingfabric is provided which is so constituted, structurally, as to reducegreatly the amount of yarn required per unit of area. By reason of thesubstantial reduction in yarn requirements, materials such as jute maybe used with greater convenience and economy but, advantageously, yarnsformed of alternative materials, such as twisted kraft paper areemployed. The new backing material is capable of substantially moreeconomical manufacture than the conventional fabrics, and alternativematerials, such as kraft paper, may be used to great advantage becauseof their ready availability.

In general, the new cushion backing fabric is comprised of widely spacedwarp and filler yarns, and relatively wide, fiat warp ribbons disposedbetween sets of warp yarns in a manner to provide a surface of asubstantially continuous nature. Where the cushion material is to bepoured onto the backing, the fabric may be provided with sufficientinterstices to receive the poured material and form a mechanicalinterlock therewith. Advantageously, though not necessarily, the warpyarns are arranged in pairs, and between each pair extends a warpribbon. The ribbons may be in the range of about onefourth to one-halfinch in width, for example, and in some cases even wider, so that, inthe completed fabric structure, there may be in the order of four warpyarns per inch of fabric width. In addition, the fabric structureaccommodates substantial spacing of the weft or filler yarns, which maybe about one-eighth inch to one-fourth inch apart, for example.

The new fabric presents a substantially continuous surface,notwithstanding the wide spacing of the yarns, by reason of theincorporation of wide warp ribbons in the I time structure. Thecompleted fabric has strength and dimensional stability which is Whollyadequate for the intended end use, and the fabric has a unique andpleasing appearance, which may be heightened by utilizing contrastingcolors for the yarns and ribbons.

In the manufacture of the new fabric, conventional looms may beemployed, with minimal modification of the heddles, for example, toaccommodate the wide warp ribbons. Operation of the equipment is, infact, substantially simplified, by reason of the substantial reductionin the required yarn supplies.

For a better understanding of the invention and for a further discussionof the above and other advantageous features thereof, reference shouldbe made to the following detailed specification and to the accompanyingdrawing, in which:

FIG. 1 is a fragmentary plan View of a rug cushion or the likeincorporating backing fabric according to the invention; and

FIGS. 2 and 3 are cross-sectional views taken along lines 22 and 3-3,respectively.

Referring now -to the drawing, the reference numeral 10 designates,generally, the new fabric, which is incorporated in and forms the topsurface of a rug cushion 11, the lower portion of the cushionadvantageously comprising a layer 12 of foamy, resilient material, suchas foam rubber. In accordance with the invention, the fabric 10 is awoven fabric comprising warp threads 13, 14, which, in the illustratedfabric, are arranged in pairs and spaced across the width of the web.Where desirable or expedient, the warp yarns may be made somewhatheavier and arranged individually, instead of in pairs, as will beunderstood. Each pair of warp yarns in the illustrated fabric comprisesone thread of each of two sets, and the pairs are spaced widely apart inrelation to yarn thickness, on centers of, for example, about one-fourthto onehalf inch or more. Extending Widthwise of the fabric are weft orfiller yarns 15, 16, which are returned at the edges of the web and formwith pairs of edge warps 17, 18, a selvedge. Advantageously, the filleryarns are spaced apart, lengthwise of the fabric, about one-eighth toone-fourth inch.

Extending lengthwise of the fabric, between the pairs of warp yarns 13,14, are warp ribbons 19, 20 formed of wide, fiat material, such as kraftpaper, having a basis Weight of about 60 pounds. In accordance with theinvention, the warp ribbons are of substantial width in relation to thethickness of the yarns and, by way of example, the ribbons may be in therange of about onefourth to one-half inch or more in width, while theyarn thickness may be on the order of one thirty-second inch.

Although kraft paper of 60 pound basis weight is presently deemed mostsuitable for the warp ribbons, lighter or heavier materials may be usedwhere desirable or expedient. By way of example and not of limitation, arange of basis weight extending from 30 to pounds should be suitable formost applications. The heavier paper may be desirable where, forexample, it is intended to employ chain conveyors in the manufacturingprocess. In addition, in such cases, it may be desirable to employ apaper having a fair amount of wet strength, as well as a special finish.

In the illustrated fabric, adjacent warp ribbons 1.9, 20 are ofdifierent sets. That is, the ribbons 20 pass over the filler yarns 16and under the filler yarns 15, while the ribbons 19 pass over the yarns15 and under the yarns 16. Adjacent ribbons thus pass alternately overand under the filler yarns in opposite relation. Likewise, the yarns 13,14 of each pair, each being of a different set, pass alternately overand under the filler yarns 15, 16 in opposite relation. In addition, thewarp yarns weave in opposition to the nearest warp ribbon, so that thewarp yarns directly adjacent a particular ribbon are of the same set. Byway of example, the ribbons 19 are flanked by warp yarns 13, while theribbons 20 are flanked by yarns 14. V

Advantageousiy, the weave of the fabric is fairly open, as indicated inFIG. 1, to provide small interstices between the warp threads andribbons. These interstices are relatively small in relation to thesurface expanse of the fabric, however, so that a substantially full orcontinuous supporting surface is presented.

The selvedge or edge warps may be of any convenient number, to provide asatisfactory edge structure and, if desired, certain of these warp yarnsmay be colored to provide for distinctiveness or identification.

As Will be observed, the backing fabric It) has a minimum of yarns inrelation to fabric area and, advantageously, about four yarns per inch,in both directions, may be provided, although about two warp yarns perinch may suffice if single yarns, rather than pairs, are used betweenwarp ribbons. In view of such sparing use of yarns, it is practical andexpedient to form the yarns of a twisted kraft paper which may have anopen width of, for example, one-fourth inch. Advantageously, the yarnhas a minimum amount of twist, providing for economy of manufacture.

The new fabric may be manufactured by conventional Weaving techniques,in plain or other weave, with only minimal and simplified alterationsbeing required of the looms. The heddles and reeds are, of course,opened up where necessary to accommodate the wide warp rib bons. Thecreel may be simplified substantially, due to the great reduction in thenumber of warp yarn supplies and, advantageously, the warp ribbons maybe supp-lied from slit rolls straight off the cutter bar or fromseparate pads supported in front of the creel, preferably below theyarns for ease of access.

The manufacture of rug cushions using the new fabric may be carried outin the conventional manner, either by pouring the cushion material overthe fabric, leveling the material at an appropriate thickness, sayonefourth inch, and curing the material, or by 'adhesively securing apreformed layer of the cushion material to the backing. When poured overthe backing fabric, the cushion material is in a viscous state, so thatit enters the interstices between the warp yarns and ribbons and becomesmechanically interlocked with the fabric. The poured cushion layer isillustrated in representative fashion in FIGS. 2 and 3, and it will beobserved therein that portions of the cushion material extend throughthe fabric interstices adjacent the fabric-cushion interface, to forminterlocks, as indicated at 21, 22, for example. The backing fabricforms a support for the cushion material during the pouring thereof but,when the cushion is in use, the backing fabric comprises the top surfacethereof. The foamy material grips the floor well, and provides a softbase or cushion pad, while the backing fabric imparts desirabledimensional stability to the cushion material and also provides a topsurface over which a rug or carpet may be slipped for adjusting itsposition.

One of the outstanding advantages of the invention resides in the lowcost of the backing fabric in relation to known fabrics used for thesame purpose. Thus, the new fabric has a cost basis in the region of21%34% below conventional jute fabrics. Rug cushions incorporatingbacking fabrics of the new type, made of kraft paper yarns and ribbons,also have improved physical characteristics, resulting from thesubstantial dimensional stability of the paper elements of the fabric.Thus, in addition to improved stretch resistance, the new cushion ishighly resistant to wrinkling, buckling and to the formation ofscalloped edges, all of which cause substantial problems in the layingof carpet with known cushions. The new fabric is also readily made tosubstantial widths, such as 912'-15', enabling the manufacture ofseamless cushions to such widths.

It should be understoodthat the specific forms of the invention hereinillustrated and described are intended to be representative only, ascertain changes may be made therein without departing from the clearteachings of the disclosure. By way of example only and not oflimitation, it may be advantageous to utilize creped paper for the warpribbons, affording a degree of resiliency to facilitate weaving and toprovide improved adherence to the foam cushion material. Accordingly,reference should be made to the following appended claim in determiningthe full scope of the invention.

I claim:

The combination of a fabric and foam cushion material, said fabriccomprising warp threads spaced at least one-fourth inch apart across thewidth of the fabric, filler threads extending widthwise of the fabricand spaced lengthwise thereof, said threads being formed of twistedkraft paper, .and relatively wide flat warp ribbons formed of kraftpaper having a basis weight in the range of about 30-90 pounds, saidribbons extending lengthwise of the fabric between said warp threads andbeing generally of the same width as the spacing of said warp threads,said warp threads passing alternately over and under the filler threads,the weave of said fabric being relatively loose to form intersticesbetween adjacent threads and ribbons, said foam cushion material havingportions which interlock with the. threads and ribbons of the fabric inthe region of the fabric-cushion interface and in the regions of saidinterstices between said adjacent threads and ribbons.

References Cited in the file of thispatent UNITED STATES PATENTS

